High stability stacked warp yarn dryer fabric with long warp floats

ABSTRACT

An industrial textile is provided, preferably suitable for use as a dryer fabric in a papermaking machine. The industrial textile has first and second surfaces and is defined by first and second systems of warp yarns interwoven with a system of weft yarns in a repeating pattern. In the repeating pattern, each of the warp yarns in the first system of warp yarns is interwoven with the system of weft yarns with a float on the first surface over at least 5 of the weft yarns, under 1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weft yarns. Additionally, each of the warp yarns in the second system of warp yarns is interwoven with the system of weft yarns with a float on the second surface under at least 5 of the weft yarns, over 1 of the weft yarns, under 1 of the weft yarns, and over 1 of the weft yarns in the repeating pattern. Each of the warp yarns of the first system of warp yarns is stacked over a corresponding one of the warp yarns of the second system of warp yarns to form stacked pairs of the warp yarns.

BACKGROUND

The invention relates to industrial textiles, and more particularly topapermaking fabrics.

Numerous weaves are known in the art which are employed to achievedifferent results for different applications.

WO 2011/022831, which is assigned to the assignee of the presentinvention, discloses a dryer fabric for a papermaking machine havingstacked warp yarns with about 193% warp fill woven with filler wefts andcritical picks.

U.S. Pat. No. 9,365,958 is directed to a stretchable fabric for clothingthat is a single layer woven with long floats and is unrelated topapermaking fabrics or industrial conveying fabrics used in papermakingor filtration operations. There is therefore no need or concern withincreasing the life of an industrial fabric, and in particular, apapermaking fabric by providing a machine side surface dominated by longmachine direction (MD) floats for increased wear resistance.

SUMMARY

The invention concerns an industrial textile, preferably suitable foruse as a dryer fabric in a papermaking machine. The industrial textilehas first and second surfaces and is defined by first and second systemsof warp yarns interwoven with a system of weft yarns in a repeatingpattern. In the repeating pattern, each of the warp yarns in the firstsystem of warp yarns is interwoven with the system of weft yarns on thefirst surface over at least 5 of the weft yarns, under 1 of the weftyarns, over 1 of the weft yarns, and under 1 of the weft yarns forming afloat on the first surface over the at least 5 of the weft yarns.Additionally, each of the warp yarns in the second system of warp yarnsis interwoven with the system of weft yarns on the second surface underat least 5 of the weft yarns, over 1 of the weft yarns, under 1 of theweft yarns, and over 1 of the weft yarns in the repeating patternforming a float on the second surface under the at least 5 of the weftyarns. Each of the warp yarns of the first system of warp yarns isstacked over a corresponding one of the warp yarns of the second systemof warp yarns to form stacked pairs of the warp yarns.

In one embodiment, the float on the first surface is over 7 weft yarns,and the float on the second surface is under 7 weft yarns.

Preferably, the system of weft yarns includes alternating largerdiameter filler wefts and smaller diameter critical picks.

In one preferred arrangement, the warp yarns of the first system of warpyarns only weave under the critical picks, and the warp yarns of thesecond system of warp yarns only weave over the critical picks.

Preferably, the repeating pattern of the warp yarns of the first systemof warp yarns of under 1 of the weft yarns, over 1 of the weft yarns andunder 1 of the weft yarns forms a locking weave for maintaining aposition of the warp yarns of the first system of warp yarns, and therepeating pattern of the warp yarns of the second system of warp yarnsof over 1 of the weft yarns, under 1 of the weft yarns, and over 1 ofthe weft yarns forms a locking weave for maintaining a position of thewarp warns of the second system of warp yarns. In prefered arrangementsfor certain filter fabrics, this allows the stacked pairs of the warpyarns to be spaced apart to form an open mesh pattern while stillmaintaining a high stability for the industrial textile. On onepreferred arrangement, the stacked pairs of the warp yarns are spacedapart by at least 40% of a cross-direction dimension of one of the warpyarns.

In one preferred arrangement, the floats on the first surface arearranged with a diagonal twill.

In one embodiment, the first system of warp yarns is made from adifferent material than the second system of warp yarns.

In several of the preferred arrangements, the warp yarns of the firstand second systems of warp yarns have a rectangular cross-section.Preferably, the cross-section of the warp yarns of the first and secondsystems of warp yarns are the same. Preferably, the weft yarns have acircular cross-section. However, this can be varied. The warp and/orweft yarns may be grooved and/or profiled in the manner described byU.S. Pat. No. 6,773,786 to assist in rendering the fabric contaminationresistant.

For a preferred application, the first system of warp yarns and secondsystem of warp yarns each have at least about 96% warp fill. This isparticulary useful for dryer fabrics for papermaking machines.

In one arrangement where the floats in the first and second systems ofwarp yarns are over 5 of the weft yarns on a top surface and under 5weft yarns on a bottom surface, the industrial textile is woven with an8 shed, 10 step pattern. Depending on the length of the warp floats, thenumber of steps needed to weave the industrial textile may need to beincreased.

As noted above, the present industrial textile has preferredapplications as a papermaking fabric. The industrial textile ispreferably flat woven, and the ends are seamed to form an endless beltthat can then be used in papermaking applications on a papermakingmachine. One preferred application is a dryer fabric for a papermakingfabric.

The resulting constructions are a rugged and wear resistant industrialtextile that resists warp nesting and canting and is highly stable(meaning it is resistive to out of plane distortion due in part to itsdiagonal stability). The fabric is adaptable to a wide range ofapplications by appropriate selection of warp and weft yarn types, sizesand shapes. For example, air permeability of the fabric is easilyadjusted according to need; the fabric can be rendered temperature orcontamination resistant by appropriate selection of the warp yarnmaterials and sizes. In addition the fabric provides for high seamstrength due to the stacked warp construction which preferably utilizesapproximately 100% of the warp yarns to form the seam, and which alsoprovides the fabric with approximately 200% warp fill. The term “warpfill” refers to the amount of warp yarns in a given space relative tototal space considered. Warp fill can be over 100% when there are morewarp strands jammed into the available space than the space candimensionally accommodate in a single plane. A fabric with approximately200% warp fill or more may have two layers of warp yarns each woven atat least approximately 100% warp fill. In this context, those skilled inthe art would understand that 190% to 210% would be consideredapproximately 200% warp fill. The fabric can be highly stable, andresists creasing and distortion when the warp yarns in each layer arewoven at 100% warp fill, or more, and are thus immediately adjacent toand braced against one another. This in combination with the lockingweave of the warp yarns provides enhanced stability in combination withincreased longevity due to the long warp floats. The weave pattern ofthe novel fabrics provide long floats of the warp yarns on both exteriorsurfaces that enhance the ability of these fabrics to resist abrasivewear.

The fabric design can be adapted for many different applications byproper warp and weft selection which will allow the fabric to obtain awide range of air permeabilities. Although fabric caliper (thickness)can be made low to allow for use in high speed applications, thestability of the textile is maintained due to the warp yarn bracing andlocking weave provided with the weft yarns. The two independent warpsystems provide a further benefit in that the materials used in each canbe optimized to resist the environmental effects to which each fabricsurface is exposed. For example, the monofilament warp yarns used toform a first fabric surface can be comprised of PPS (polyphenylenesulfide) or PCTA (polycylcohexane dimethanol terephthalic acid) polymerswhich are more resistant to thermal and hydrolytic degradation than PET(polyethylene terephthalate) yarns (and more expensive). Warp yarnsformed from PET polymer could be utilized on the paper side of thetextile (in papermaking applications) where heat and hydrolysisresistance are less critical properties.

Fabrics according to the invention such as are shown in the Figures werewoven using rectangular cross-section polymeric monofilament warp yarnswhose dimensions are 0.25×1.05 mm or 0.36×1.07 mm to obtain a width toheight ratio of between 4:1 and 3:1, but other cross-sectional shapesand ratios may be employed. The weft yarns used in these fabrics have agenerally circular cross-sectional shape and range in size from about0.50 mm to 1.0 mm; although other sizes may be employed depending uponthe specific application.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing Summary and the following detailed description will bebetter understood when read in conjunction with the appended drawings,which illustrate a preferred embodiment of the invention. In thedrawings:

FIG. 1 is a weave diagram showing a first embodiment of an industrialtextile having the present construction.

FIG. 2 is a cross-sectional view showing the weave pattern of two of thestacked warp yarns in the fabric construction shown in FIG. 1.

FIG. 3 is a top view of a second embodiment of an industrial textile ofthe present construction.

FIG. 4 is a cross-sectional view showing the weave paths of two pairs ofstacked warp yarns shown in FIG. 3.

FIG. 5 is a top view of an industrial textile according to a thirdembodiment of the present construction.

FIG. 6 is a cross-sectional view showing the weave path of two pairs ofthe stacked warp yarns shown in FIG. 5.

FIG. 7 is a weave diagram showing a fourth embodiment of an industrialtextile having the present construction.

FIG. 8 is a cross-sectional view showing the weave pattern of two of thestacked warp yarns in the fabric construction shown in FIG. 7.

FIG. 9 is a weave diagram of a fifth embodiment of an industrial textilehaving a high stability construction.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Certain terminology is used in the following description for convenienceonly and is not limiting. The fabric according to the invention is anindustrial textile, which can have many industrial applications, such asconveyor belts, filtration fabrics, specialty fabrics for non-wovenapplications, etc. The words “paper side” (PS) and “machine side” (MS)designate surfaces of the fabric with reference to their use in onepreferred application in a papermaking machine; however, these termsmerely represent first and second or upper and lower surfaces of theplanar fabric. “Yarn” is used to generically identify a monofilament ormultifilament fiber. “Warp” and “weft” are used to designate yarns ormonofilaments based on their position in the loom that extend inperpendicular directions in the fabric and either could be a machinedirection (MD) or cross-machine direction (CMD) yarn in the fabric onceit is installed on a papermaking machine, depending on whether thefabric is flat woven or continuously woven. In the preferredarrangement, the fabric is flat woven and seamed at the warp ends inorder to form a continuous belt, so that the warp yarns are MD yarns andthe weft yarns are CMD yarns.

One preferred application of the fabrics according to the invention ison a papermaking machine, and the fabric could have application as abase for a press fabric, or a dryer fabric for use in the correspondingpress and dryer sections of a papermaking machine. These are generallyall referred to as a “papermaking fabric” regardless of the position ofuse in a papermaking machine. Other applications include filtrationfabrics, as well as other non-woven applications.

Referring to FIGS. 1 and 2, an industrial textile 20 in accordance witha first preferred embodiment of the present construction is illustratedusing a weave diagram (FIG. 1) and a cross-section taken along the MD.The industrial textile 20 includes a first surface 24 and a secondsurface 26. In one preferred construction as a papermaking fabric, thefirst surface 24 corresponds to the PS and the second surface 26corresponds to the MS.

The industrial textile 20 is woven with first and second systems of warpyarns 21, 22, which are interwoven with a system of weft yarns 30 in arepeating pattern. The warp yarns are identified as warp yarns 1-16,with the first group of warp yarns including the even numbered warpyarns, i.e., 2, 4, 6, 8, 10, 12, 14, 16, and the second system of warpyarns including the odd numbered warp yarns, i.e. 1, 3, 5, 7, 9, 11, 13,15. The weft yarns 31-40 are interwoven with the warp yarns 1-16, ofwhich preferably there are alternating larger diameter filler wefts 31,33, 35, 37, 39, and a smaller diameter critical picks 32, 34, 36, 38,40. Each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the firstsystem of warp yarns 21 is interwoven with the system of weft yarns 30with a float on the first surface 24 over at least five of the weftyarns 31-40. In the first embodiment of the industrial textile 20, thefloats of each of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the firstsystem of warp yarns 21 are over 7 of the weft yarns 31-40. This isshown in connection with the warp yarn 2 in FIG. 2 and would be true foreach of the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system ofwarp yarns 21. In order to form a locking weave each of the warp yarns2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 thenextends under one of the weft yarns 32, 34, 36, 38, 40, over one of theweft yarns 31, 33, 35, 37, 39, and under another one of the weft yarns32, 34, 36, 38, 40 in the repeating pattern. Preferably the warp yarns2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 onlyweave under the critical picks 32, 34, 36, 38, 40. Preferably, the firstand second systems of warp yarns 21, 22 are woven with 8 sheds in 10steps.

Each of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system ofwarp yarns 22 is interwoven with the system of weft yarns 30 with afloat on the second surface 26 under at least five of the weft yarns31-40. In the first embodiment 20, preferably the warp yarns 1, 3, 5, 7,9, 11, 13, 15 in the second system of warp yarns 22 are interwoven withthe system of weft yarns 30 with a float on the second surface under 7of the weft yarns 31-40. In order to form the locking weave, the warpyarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system of warp yarns 22then weave over one of the weft yarns 32, 34, 36, 38, 40 under one ofthe weft yarns 31, 33, 35, 37, 39, and over one of the weft yarns, 32,34, 36, 38, 40 in the repeating pattern. As shown, each of the warpyarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns 21 isstacked over a corresponding one of the warp yarns 1, 3, 5, 7, 9, 11,13, 15 of the second system of warp yarns 22 to form stacked pairs ofwarp yarns. As illustrated in FIG. 2, warp yarn 2 is stacked over warpyarn 1. With respect to the weave diagram shown in FIG. 1, the evennumbered warp yarns 2, 4, 6, 8, 10, 12, 14, 16 in the first system ofwarp yarns 21 are stacked over the corresponding ones of the oddnumbered warp yarns 1, 3, 5, 7, 9, 11, 13, 15 in the second system ofwarp yarns 22. The warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the secondsystem of warp yarns 22 only weave under the critical picks 32, 34, 36,38, 40 which have the smaller diameter D2 than the filler wefts 31, 33,35, 37 which have a larger diameter D1. The repeating pattern of thewarp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warp yarns21 of under one of the weft yarns, over one of the weft yarns and underone of the weft yarns forms a locking weave for maintaining a positionof the warp yarns 2, 4, 6, 8, 10, 12, 14, 16 of the first system of warpyarns 21 in position within the industrial textile. The repeatingpattern of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 of the second systemof warp yarns 22 of over one of the weft yarns, under one of the weftyarns, and over one of the weft yarns, also forms a locking weave formaintaining a position of the warp yarns 1, 3, 5, 7, 9, 11, 13, 15 ofthe second system of warp yarns 22 in position.

In a preferred arrangement of the industrial textile 20, 100% warp fillis provided for each of the first and second systems of warp yarns 21,22, which, in combination with the locking weaves, provide an extremelystable fabric 20.

In a preferred arrangement, the warp yarns 1-16 preferably have arectangular cross-sectional shape which contributes to the stability ofthe fabric 20 and its smoothness. The warp yarns 1-16 are preferablymonofilaments formed of a polymeric material. In one embodiment, thedimensions are 0.25×1.05 mm or 0.36×1.07 mm to obtain a width to heightratio of between 4:1 and 3:1. Those skilled in the art will recognizethat other cross-sectional shapes and ratios may also be used, such asoval or flattened shapes with rounded sides and aspect ratios of 2:1 to6:1. The weft yarns 31-40 preferably have a circular cross-sectionalshape that in some preferred arrangements may range in size from 0.6 mm,0.7 mm, 0.8 mm, or 0.9 mm. Other sizes may also be used depending on theintended application for the fabric. In one preferred arrangement, thefabric 20 is woven at 22 picks per inch (weft yarns per inch) (8.7yarns/cm).

The use of first and second systems of warp yarns, 21, 22 also allowdifferent materials to be used for the first and second system of warpyarns 21, 22 in order to provide optimal materials on the first andsecond surfaces 24, 26, of the industrial textile 20 for the preferredapplication.

For example, the monofilament warp yarns 2, 4, 6, 8, 10, 12, 14, 16 ofthe first system of warp yarns 21 used to form the first surface 24 canbe comprised of PPS (polyphenylene sulfide) or PCTA (polycylcohexanedimethanol terephthalic acid) polymers which are more resistant tothermal and hydrolytic degradation than PET (polyethylene terephthalate)yarns (and more expensive). The warp yarns 1, 3, 5, 7, 9, 11, 13, 15 ofthe second system of warp yarns can be formed from PET polymer since thePS of the textile (at least in papermaking applications) is where heatand hydrolysis resistance are less critical yarn properties. Thoseskilled in the art will understand from the present disclosure thatthese materials are merely exemplary, and that other materials could beused depending on the particular application. These warp yarns 1-16 maybe grooved, profiled, coated, or otherwise treated for contaminationresistance.

Additionally, due to the long warp floats, a higher contact area can beachieved that reduces fabric wear rates in comparison to similar fabricshaving more defined knuckles due to the weave. The long warp floats alsoprovide for benefits in contamination resistance in comparison tosimilar weft proud fabrics.

Preferably, industrial textile 20 is formed into a continuous loop foruse as a papermaking fabric, and more particularly as a papermakingdryer fabric, for use on a papermaking machine. In order to form theloop, a seam is created at the ends of the warp yarns 1-16. Preferably,the seam uses 100% of the warp yarns to form the seam. Seams can beformed in a known manner by unweaving and back-weaving warp yarns fromthe first system of warp yarns 21 back into the fabric along the pathsof the corresponding stacked ones of the warp yarns from the secondsystem of warp yarns 22 that have been cut back from the end of thefabric to form seam loops at each end of the planar fabric, with theseam loops then being interdigitated and joined by a pintle to form anendless fabric loop. Other types of seaming, such as QuickLink seam,which was developed by AstenJohnson, the assignee of the presentinvention, can also be utilized. In a preferred arrangement forpapermaking, the warp fill is preferably about 200% warp fill, with eachlayer having warp yarns woven at about 100% warp fill. This contributesto the stability of the industrial textile 20 and helps to resistcreasing and distortion due to the fact that the warp yarns 1-16 in eachlayer are woven at about 100% warp fill, and thus are immediatelyadjacent to and braced against one another. This in connection with thelocking weave provides enhanced fabric stability for the industrialtextile 20.

Referring to FIGS. 3 and 4, a second embodiment of an industrial textile120 is shown. The industrial textile 120 is similar to the industrialtextile 20 and includes first and second systems of warp yarns 121, 122that are interwoven with a system of weft yarns 130. The arrangement issimilar to the industrial textile 20 with the exception that the floatsin the first warp system 121 are over five of the weft yarns 131-138 andthe floats in the second system of warp yarns 122 are under 5 of theweft yarns 131-138. The warp yarns 102, 104 of the first system of warpyarns 121 are woven in stacked pairs over the warp yarns 101, 103 of thesecond system of warp yarns 122 as shown. The warp yarn 102 weaves overweft yarns 131-135, under weft yarn 136 over weft yarn 137 and underweft 138. As in the first embodiment, the weft yarns 132, 134, 136, 138are critical pics having a smaller diameter than the filler wefts 131,133, 135, 137. The warp yarn 101 of the second system of warp yarns 122,which is stacked under the warp yarn 102, weaves under weft yarn 131,over weft yarn 132, under weft yarn 133, over weft yarn 134, and thenunder weft yarns 135-138. The next stacked pair of warp yarns 104, 103are woven with the warp yarn 104 extending over weft yarn 131, underweft yarn 132, over weft yarn 133, under weft yarn 134, and over weftyarns 135-138. The warp yarn 103 which is stacked under the warp yarn104 weaves under weft yarns 131-135 over weft yarn 136, under weft yarn137, and over weft yarn 138. This stacked arrangement of warp yarns101-104 extends across the fabric width in an alternating arrangement asshown in FIG. 3. As in the industrial textile 20, the warp yarns 102,104 of the first system of warp yarns 121 only weave under the criticalpics 132, 134, 136, 138 and the warp yarns 101, 103 of the second systemof warp yarns 122 only weave over the critical pics 132, 134, 136, 138.As in the first embodiment of the industrial textile 20, each of thewarp yarns 102, 104 in the first system of warp yarns 121 forms alocking weave after each float by weaving under one of the weft yarns132, 134, 136, 138 over one of the weft yarns 131, 133, 135, 137 andunder one of the weft yarns 132, 134, 136, 138. Similarly, the warpyarns 101, 103 of the second system of warp yarns 122 form a lockingweave after each of the floats by weaving over one of the weft yarns132, 134, 136, 138, under one of the weft yarns 131, 133, 135, 137, andover one of the weft yarns 132, 134, 136, 138. This provides enhancedstability for the fabric 120 which is also preferably woven with 100%warp fill in each of the first system of warp yarns 121 and the secondsystem of warp yarns 122. The warp yarns 101-104 and the weft yarns131-138 are similar to the warp yarns 1-16 and weft yarns 31-40 asdescribed above in connection with the first embodiment of theindustrial textile 20. As shown in FIG. 3, this arrangement provides adiagonal twill on the first surface 124 of the industrial textile 120. Adiagonal twill would also be provided on the second surface 126.

Referring now to FIGS. 5 and 6, a third embodiment of the industrialtextile 120′ is shown. The third embodiment of the industrial textile120′ is woven with the same repeating weave pattern as the secondembodiment of the industrial textile 120 and similar elements have beenmarked with the same reference numbers as in the second embodiment witha prime. For example, the warp yarns 101′-104′ correspond to the warpyarns 101-104 in the second embodiment 120, and the weft yarns 131′-138′correspond with the weft yarns 131-138 of the second embodiment 120. Theprimary difference is that based on the locking weave provided for thewarp yarns 101′-104′, the warp yarns 101′-104′ in each of the layers arewoven with less than 80% warp fill in order to provide an open mesh. Ina preferred embodiment, the first system of warp yarns 121′ is wovenwith approximately 50% warp fill and the second system of warp yarns122′ is also woven with approximately 50% warp fill so that an open meshdryer fabric as shown in FIG. 5 can be produced. The stacked pairs ofwarp yarns 102′, 101′, and 104′, 103′, are maintained in position bytheir locking weave as discussed above in connection with the industrialtextile 120. This allows for further applications of the industrialtextiles according to the invention.

Preferably the industrial textiles 120, 120′ are formed into endlessbelts by seaming at the warp ends as discussed above in connection withthe first embodiment of the industrial textile 20. A preferredapplication for the industrial textile 120 is as a papermaking fabric,and in particular, a dryer fabric for a papermaking machine.

A preferred application for the industrial textile 120′ is for use as adryer fabric. However, those skilled in the art will recognize thatthere are other applications.

Referring to FIGS. 7 and 8, a fourth embodiment of an industrial textile220 is shown. The industrial textile 220 is similar to the industrialtextile 20 and includes first and second systems of warp yarns 221, 222that are interwoven with a system of weft yarns 230. The arrangement issimilar to the industrial textile 20 with the exception that the floatsin the first warp system 221 are over seven of the weft yarns 231-242and the floats in the second system of warp yarns 222 are under 7 of theweft yarns 231-242. The warp yarns 202, 204, 206, 208, 210, 212, 214,216 of the first system of warp yarns 221 are woven in stacked pairsover the warp yarns 201, 203, 205, 207, 209, 211, 213, 215 of the secondsystem of warp yarns 222 as shown. The warp yarn 202 weaves over weftyarns 231-237, under weft yarn 238 over weft yarn 239 and under weft240. In a similar manner to the first embodiment, the weft yarns 232,234, 236, 238, 240, 242 are critical pics having a smaller diameter thanthe filler wefts 231, 233, 235, 237, 239. 241. The warp yarn 201 of thesecond system of warp yarns 222, which is stacked under the warp yarn202, weaves under weft yarn 231, over weft yarn 232, under weft yarn233, over weft yarn 234, and then under weft yarns 235-242. The nextstacked pair of warp yarns 204, 203 are woven with the warp yarn 204extending over weft yarn 231, under weft yarn 232, over weft yarn 233,under weft yarn 234, and over weft yarns 235-242. The warp yarn 203which is stacked under the warp yarn 204 weaves under weft yarns 231-237over weft yarn 238, under weft yarn 239, and over weft yarn 240, underweft yarn 241, and over weft yarn 242. The weave diagram in FIG. 7 showsthe paths of the remaining stacked pairs of warp yarns in a clearlydefined manner, and in this embodiment, the warp pattern repeats withwarp yarns 205-208 having the same weave pattern as warp yarns 201-204.The stacked arrangement of warp yarns 201-216 extends across the fabricwidth. As in the industrial textile 20, the warp yarns 202, 204, 206,208, 210, 214, 216 of the first system of warp yarns 221 only weaveunder the critical pics 232, 234, 236, 238, 240, 242 and the warp yarns201, 203, 205, 207, 209, 211, 213, 215 of the second system of warpyarns 222 only weave over the critical pics 232, 234, 236, 238, 240,242. As in the first embodiment of the industrial textile 220, each ofthe warp yarns 202, 204, 206, 208, 210, 212, 214, 216 in the firstsystem of warp yarns 221 forms a locking weave after each float byweaving under one of the weft yarns 232, 234, 236, 238, 240, 242 overone of the weft yarns 231, 233, 235, 237, 239, 241 and under one of theweft yarns 232, 234, 236, 238, 240, 242. Similarly, the warp yarns 201,203, 205, 207, 209, 211, 213, 215 of the second system of warp yarns 222form a locking weave after each of the floats by weaving over one of theweft yarns 232, 234, 236, 238, 240, 242 under one of the weft yarns 231,233, 235, 237, 239, 241 and over one of the weft yarns 232, 234, 236,238, 240, 242. This provides enhanced stability for the fabric 220 whichis also preferably woven with 100% warp fill in each of the first systemof warp yarns 221 and the second system of warp yarns 222. The warpyarns 201-216 and the weft yarns 231-242 are similar to and can have thesame constructions as the warp yarns 1-16 and weft yarns 31-40 asdescribed above in connection with the first embodiment of theindustrial textile 20. As shown in FIG. 7, this arrangement provides adiagonal twill on the first surface 224 of the industrial textile 220. Adiagonal twill would also be provided on the second surface 226.

FIG. 9 shows a further alternative embodiment of a high stabilityindustrial textile 320 is shown. The industrial textile 320 includesfirst and second systems of warp yarns 321, 322 that are interwoven witha system of weft yarns 330. Here, the floats in the first warp system321 are over at least 5, and preferably over seven of the weft yarns331-338 and the floats in the second system of warp yarns 322 are underat least 5 and preferably under 7 of the weft yarns 331-338. The warpyarns 301-316 are woven in adjacent pairs that are stacked. Adjacentwarp yarns 303, 304 are arranged on the first surface 324 and are wovenalong the same path over at least 5 of the weft yarns 331-338, and arestacked over adjacent warp yarns 301, 302 which are arranged on thesecond surface 326 and are woven along the same path under at least 5 ofthe weft yarns 331-338. Adjacent first surface warp yarns 307, 308 arealso woven along the same path and are stacked over adjacent secondsurface warp yarns 305, 306 which are woven along the same path.Similarly, adjacent first surface warp yarns 311, 312 are also wovenalong the same path over at least 5 of the weft yarns 331-338 and arestacked over adjacent second surface warp yarns 309, 310 that are wovenalong the same path under at least 5 of the weft yarns, and adjacentfirst surface warp yarns 315, 316 are also woven along the same pathover at least 5 of the weft yarns 331-338 and are stacked over adjacentsecond surface warp yarns 313, 314 that are woven along the same pathunder at least 5 of the weft yarns. The weave diagram in FIG. 9 showsthe repeat, and in this example, the warp yarn floats are over/under 7of the weft yarns 331-338. Based on the paired arrangement of the warpyarns 301-316 in the first surface 324 and the second surface 326, adistinct double float arrangement is provided with a distinct diagonaltwill. As shown, the warp yarns 303, 304 of the first system of warpyarns 321 weave over weft yarns 331-337, and under weft yarn 338. Thewarp yarns 301, 302 of the second system of warp yarns 322, which arestacked under the warp yarns 303, 304, weave under weft yarns 331-333,over weft yarn 334, and under weft yarns 335-338. The next adjacent pairof warp yarns 307, 308 are woven as an adjacent pair over weft yarns231-233, under weft yarn 234, and over weft yarns 235-238. The adjacentwarp yarns 205, 206 which are stacked under the warp yarns 207, 208weave under weft yarns 231-237, and over weft yarn 238. The arrangementof adjacent warp yarns 311, 312 of the first system of warp yarns 321over adjacent warp yarns 309, 310 of the second system of warp yarns322, as well as the arrangement of adjacent warp yarns 315, 316 of thefirst system of warp yarns 321 over adjacent warp yarns 313, 314 of thesecond system of warp yarns 322 are similar. The interweaving of thewarp yarns of the first and second systems of warp yarns 321, 322 isonly with critical pics 332,334, 336, 338, and not with the filler wefts331, 333, 335, 337. Preferably the warp fill is about 200% warp fill,with each layer having warp yarns woven at about 100% warp fill. Thiscontributes to the stability of the industrial textile 320 and helps toresist creasing and distortion due to the fact that the warp yarns301-316 in each layer are woven at about 100% warp fill, and thus areimmediately adjacent to and braced against one another.

In order to provide for smooth first and second surfaces 24, 26, of thefabric 20, as well as the first and second surfaces 124, 126; 124′,126′; 224, 226; 324, 326 of the industrial textiles 120, 120′, 220, 320preferably, the filler wefts 31, 33, 35, 37, 39; 131, 133, 135, 137;131′, 133′, 135′, 137′; 231, 233, 235, 237, 239, 241; 331, 333, 335, 337have a diameter D1 and the smaller critical pics 32, 34, 36, 38, 40;132, 134, 136, 138; 132′, 134′, 136′, 138′; 232, 234, 236, 238, 240,242; 332, 334, 446, 338 have a diameter D2 which is smaller than D1, andthe warp yarns 1-16, 101-104, 101′-104′, 210-216, 301-316 have arectangular cross-section with a thickness t. Preferably, (D1−D2)/2≈2t.This provides for generally smooth first and second surfaces in theindustrial textiles 20, 120, 120′, 220, 320. In one exemplary embodimentD1=0.90 mm, D2=0.60 mm and t=1.55 mm. Those skilled in the art willrecognize that other dimensions could be used depending on theparticular application.

Having thus described the present invention in detail, it is to beappreciated and will be apparent to those skilled in the art that manyphysical changes, only a few of which are exemplified in the detaileddescription of the invention, could be made without altering theinventive concepts and principles embodied therein. It is also to beappreciated that numerous embodiments incorporating only part of thepreferred embodiment are possible which do not alter, with respect tothose parts, the inventive concepts and principles embodied therein. Thepresent embodiment and optional configurations are therefore to beconsidered in all respects as exemplary and/or illustrative and notrestrictive, the scope of the invention being indicated by the appendedclaims rather than by the foregoing description, and all alternateembodiments and changes to this embodiment which come within the meaningand range of equivalency of said claims are therefore to be embracedtherein.

1. An industrial textile having first and second surfaces, the textilecomprising: first and second systems of warp yarns interwoven with asystem of weft yarns in a repeating pattern in which: each of the warpyarns in the first system of warp yarns is interwoven with the system ofweft yarns on the first surface over at least 5 of the weft yarns, under1 of the weft yarns, over 1 of the weft yarns, and under 1 of the weftyarns in the repeating pattern forming a float on the first surface overthe at least 5 of the weft yarns, each of the warp yarns in the secondsystem of warp yarns is interwoven with the system of weft yarns on thesecond surface under at least 5 of the weft yarns, over 1 of the weftyarns, under 1 of the weft yarns and over 1 of the weft yarns in therepeating pattern forming a float on the second surface under the atleast 5 of the weft yarns, and each of the warp yarns of the firstsystem of warp yarns is stacked over a corresponding one of the warpyarns of the second system of warp yarns to form stacked pairs of thewarp yarns.
 2. The industrial textile of claim 1, wherein the float onthe first surface is over 7 weft yarns, and the float on the secondsurface is under 7 weft yarns.
 3. The industrial textile of claim 1,wherein the system of weft yarns includes alternating larger diameterfiller wefts and smaller diameter critical picks.
 4. The industrialtextile of claim 3, wherein the warp yarns of the first system of warpyarns only weave under the critical picks, and the warp yarns of thesecond system of warp yarns only weave over the critical picks.
 5. Theindustrial textile of claim 1, wherein the repeating pattern of the warpyarns of the first system of warp yarns of under 1 of the weft yarns,over 1 of the weft yarns, and under 1 of the weft yarns forms a lockingweave for maintaining a position of the warp warns of the first systemof warp yarns, and the repeating pattern of the warp yarns of the secondsystem of warp yarns of over 1 of the weft yarns, under 1 of the weftyarns, and over 1 of the weft yarns forms a locking weave formaintaining a position of the warp warns of the second system of warpyarns.
 6. The industrial textile of claim 1, wherein the stacked pairsof the warp yarns are spaced apart to form an open mesh pattern.
 7. Theindustrial textile of claim 6, wherein the stacked pairs of the warpyarns are spaced apart by at least 40% of a cross-direction dimension ofone of the warp yarns.
 8. The industrial textile of claim 1, wherein thefloats on the first surface are arranged with a diagonal twill.
 9. Theindustrial textile of claim 1, wherein the first system of warp yarns ismade from a different material than the second system of warp yarns. 10.The industrial textile of claim 1, wherein the warp yarns of the firstand second systems of warp yarns have a rectangular cross-section. 11.The industrial textile of claim 10, wherein the cross-section of thewarp yarns of the first and second systems of warp yarns are the same.12. The industrial textile of claim 10, wherein the weft yarns have acircular cross-section.
 13. The industrial textile of claim 12, whereinthe system of weft yarns includes alternating larger filler wefts havinga diameter D1 and smaller critical picks having a diameter D2, the warpyarns of the first and second systems of warp yarns with the rectangularcross-section have a thickness t, wherein D1>D2, and (D1−D2)/2≈t. 14.The industrial textile of claim 1, wherein the first system of warpyarns and second systems of warp yarns each have at least 100% warpfill.
 15. The industrial textile of claim 1, wherein the first andsecond systems of warp yarns are woven with 8 sheds in 10 steps.
 16. Theindustrial textile of claim 1, wherein the industrial textile is apapermaking fabric.
 17. The industrial textile of claim 1, wherein theindustrial textile is a dryer fabric for a papermaking fabric.
 18. Anindustrial textile having first and second surfaces, the textilecomprising: first and second systems of warp yarns interwoven with asystem of weft yarns in a repeating pattern in which: adjacent pairs ofthe warp yarns in the first system of warp yarns are interwoven along asame path with the system of weft yarns on the first surface over atleast 5 of the weft yarns and under 1 of the weft yarns in the repeatingpattern forming adjacent pairs of floats on the first surface over theat least 5 of the weft yarns, adjacent pairs of the warp yarns in thesecond system of warp yarns are interwoven along a same path with thesystem of weft yarns on the second surface under at least 5 of the weftyarns and over 1 of the weft yarns in the repeating pattern formingadjacent pairs of floats on the second surface under the at least 5 ofthe weft yarns, and the adjacent pairs of warp yarns of the first systemof warp yarns are stacked over corresponding ones of the adjacent pairsof warp yarns of the second system of warp yarns to form stacked,adjacent pairs of the warp yarns.
 19. The industrial textile of claim18, wherein the system of weft yarns includes alternating largerdiameter filler wefts and smaller diameter critical picks.
 20. Theindustrial textile of claim 19, wherein the warp yarns of the firstsystem of warp yarns only weave under the critical picks, and the warpyarns of the second system of warp yarns only weave over the criticalpicks.